IJRET: International Journal of Research in Engineering and Technology

eISSN: 2319-1163 | pISSN: 2321-7308

INVESTIGATION ON BEHAVIOR OF RCC BEAMS WITH USED

FOUNDRY SAND AS A ALETRNATIVE MATERIAL F0R NATURAL
SAND
Vasu B A1, Shashi Kumar A2, G Narayana3
1

Post graduate Student, Department of Civil Department, S.J.C.I.T, Chickballapura, Karnataka, India
2
Assistant Professor, Department of Civil Department, S.J.C.I.T, Chickballapura, Karnataka, India
3
Professor & Head of Department of Civil Engineering, S.J.C.I.T, Chickballapura, Karnataka, India

Abstract
To produce economic concrete by mixing different ratios of fine aggregate with waste foundry sand. The fine aggregate or natural
sand can be replaced by the used or waste foundry sand for different percentages such as 15%, 25%, 35% by weight respectively
for M30 grade concrete. For M30 grade concrete is produced and tested for 7,14and 28days respectively. Form the results for
35% replacement of foundry sand increases the compressive strength. The bending strength has been determined at 28 day.
Keeping all this view the main of this research is find out the behavior of cement concrete by adding of foundry waste in to the
concrete with various percentages of used foundry sand in the cement concrete by using various tests such as compressive
strength and flexural strength.

KEYWORDS; Waste Foundry Sand, Compressive Strength, Flexural Strength.

--------------------------------------------------------------------***---------------------------------------------------------------------1. INTRODUCTION

2. EXPERIMENTAL MATERIALS

From the metal casting industry foundries the by product

from this industry and these are the large amount of metalcasting industry after using many times the used sand can be
treated as waste this waste sand is called foundry sand or
waste foundry sand.

2.1 Foundry Sand or Waste Foundry Sand

Waste foundry sand can be used in the various engineering

applications and also solve the disposal problem of foundry
sand and its chemically consisting of silica sand
These foundry sand can be used in the cement concrete to
increase the strength of the concrete, And this foundry sand
can be used as a alternative material for the natural sand or
river sand. And avoid the scarcity problem of river sand in
the country.

Foundry sand uses the high amount of metal moulding

processes. And these sand can recycled and reused in many
times and the sand remaining after using large times for
casting processes is termed as foundry sand.
This study presents the information about various uses in the
civil engineering industry and also avoids the large amount
of pollution in the earth. The foundry sand chemically
consisting of silica sand, bentonite, sea coal, resins and dust
material. And this sand used in cement concrete to increase
the strength and durability properties of the cement concrete.
The used foundry sand can be used as a alternative material
for fine aggregate or natural sand to obtain a different
properties of concrete.

In a developing country energy is the major role. By earning

carbon credit by using industry waste foundry sand for
building materials like fine aggregate, the environment
problem in the country can be solved.
Concrete is the homogeneous mixture of construction
material composed of cement, fine aggregate, coarse
aggregate, water, admixture. The mixture quantity of each
material affects the strength of harden concrete. The foundry
sand consumes large amount of sand in the earth fills and
avoid the various land pollution problem. By taking this
point various investigation are made to the concrete or low
cast concrete by replacing the fine aggregate or river sand
by waste foundry sand.
Fig1. Foundry sand

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Table 1 Design mix proportion for M30 mix

Water in Cement
FA
CA
liters
(kg/m3)
(kg/m3)
(kg/m3)
By weight

158

377

772

1090

FA fine aggregate CA- coarse aggregate

Fig 2. Chemical oxide composition in Foundry sand

2.2 Cement
The cement should be such that it should be clean grey and
lumps free. For this work the OPC (ordinary Portland
cement) is used which conforming to IS-8112 1989 and
various cement tests are conducted.

2.3 Aggregate
The aggregate should be clean and it is free from dirt and
dust. The aggregate should be well graded and gives enough
strength to the concrete to resists the load. And also the
aggregate should have higher strength, durability and lower
shrinkage and it should be economical.

2.4 Coarse Aggregate

The aggregate passing through 20mm sieve and retained
4.75mm sieve is termed as coarse aggregate. The elongation
index and flakiness index should be less than 15%.

2.5 Fine Aggregate

The aggregate passing though 4.75mm sieve is termed as
fine aggregates. The fine aggregate should be clean and free
from dirt and dust.

2.6 Water
The water is the main ingredient because it involves in the
chemical reaction between the cement. The water should be
potable and clean.

3. DESIGN MIX
The design mix for M30 is made as per IS codes. And the
same mix design is used for the various test samples. Table
1 gives the design mix proportion for M30grade concrete.

Table 2 M30 concrete mix proportions

Design mix proportion for concrete
Serial
Type of
No
Concrete W/C C FA
CA
UFS
1
C0
0.42
1 2.05
2.89
0
2
C1
0.42
1 1.74
2.89
0.31
3
C2
0.42
1 1.53
2.89
0.52
4
C3
0.42
1 1.33
2.89
0.71
W/C- water cement ration
C- cement
UFS- used foundry sand
FA - fine aggregate
CA- coarse aggregate

4. EXPERIMENTAL SET UP
Table 3 Percentage of foundry sand replacement
Type of
Replacement of fine aggregates
Serial No
concrete with used foundry sand
1
C0
Normal concrete
2
C1
15% UFS replacement
3
C2
25% UFS replacement
4
C3
35% UFS replacement

5. METHODOLOGY
The methodology involves evaluation of used foundry sand
as a alternative material for fine aggregate at different
percentages such as 15%, 25%, 35% by weight and normal
controlled concrete i.e without foundry sand. And conduct
various concrete tests to both controlled concrete and
foundry sand concrete and the results are compared for both
concretes. For cubes 150X150X150 mm size are casted total
3cubes for normal concrete and cubes for foundry sand
concrete, similarly for flexural 16 number of beams were
casted and the results were compared with each other.

6. COMPRESSIVE STRENGTH
The compressive strength tests were done by compression
testing machine .For each mix 3-cubes were tested and
average will taken. The compressive strength were made for
characteristic mix ration of 1:2.05:2.89 with the replacement
of foundry sand at various percentage i.e 15%, 25%and
35%.
Table 4 Compressive strength of cubes (150x150x150) for
M30 mix at 7, 14, 28 days
% of
SL
7DAYS
14DAYS
28DAYS
foundry
NO
MPa
MPa
MPa
sand
1
0%
21.94
25.55
32.22
2
15%
23.55
26.49
32.98
3
25%
25.72
28.56
34.09
4
35%
26.5
29.81
34.08

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M30 GRADE SPECIMEN

FXMR0
%FS(N)
FXMR1
5%FSR
FXMR2
5%FSR
FXMR3
5%FSR
FXBR0
%FS(N)
FXBR1
5%FSR
FXBR2
5%FSR
FXBR3
5%FSR

200
L
O
A 150
D
100
I
N
50

K
N

0
0

DEFLECTION IN MM @ MID SPAN

Fig2. Percentage Replacement of Foundry Sand V/S
Compressive Strength (N/mm2) of Concrete for M30 mix at
7, 14 and 28 days.

7. FLEXURAL STRENGTH
Flexural strength of RC beams were performed on loading
frame for varies mixes at 28 days curing period.

Fig3. P-delta curve for mid span

M30 GRADE SPECIMEN

L 200
O
A
D 150

7.1 Reinforcement Details

Sixteen numbers of beams were casted with and without
foundry sand. The span of the beam was 2000mm and of
size 150mm x 250mm. All specimens were tested at 28th day
from the date of casting. Reinforcement details of beam
specimens are shown in table-6.

I
100
N
K 50
N
0

Table 5 Reinforcement details

Reinforcement

SL.
NO.

Beams

FXMR0
%FS(N)
FXMR1
5%FSR
FXMR2
5%FSR
FXMR3
5%FSR
FXBR0
%FS(N)
FXBR1
5%FSR
FXBR2
5%FSR
FXBR3
5%FSR

Bottom

Top

No of
beams

NCC

2#16mm

2#8mm

FSR

2#16mm

2#8mm

FSR

2#16mm

2#8mm

FSR

2#16mm

2#8mm

DEFLECTION IN MM @ 1/3 PAN

Fig4. P-delta curve for 1/3 span
Table 6 Detailed Description of beams after Testing

NCC

2#8mm

2#8mm

FSR

2#8mm

2#8mm

FSR

2#8mm

2#8mm

FSR

2#8mm

2#8mm

NCC-Normal cement concrete FSR-Foundry sand

replacement

Values obtained
Beams

1st Crack
in (KN)

2nd Crack
(KN)

Failure
Load (KN)

NCC

40

45

48

FSR

35

45

51

FSR

35

45

53

FSR

40

50

56

NCC

110

130

139

FSR

110

130

140

FSR

130

150

152

FSR

120

140

154

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8. CONCLUSION

BIOGRAPHIES

Based on the experimental results on compressive strength

and flexural strength the following conclusions are made:
1. As the percentage of foundry sand increases the
compressive strength also increases.
2. For 35% of foundry sand replacement the compressive
strength is optimum.
3. The various environmental problem can be avoid by
using this research.
4. From flexural behavior test results of load at first crack,
second crack and failure load it may be observed that the
behavior of USF replaced concrete beams were slightly
larger than that of NCC RC beams.
5. Failure load of USF replaced concrete beams were
slightly higher than that of NCC.

ACKNOWLEDGEMENTS
I am thankful to Mr. Shashi kumar A and Dr.G Narayana for
their guidance. I also thank department of civil engineering
S J C institute of technology, chickallapura. And last but not
the least my dear friends who have supported me to
complete this project work.

Vasu B A, Pursuing Final Year M- tech in

Structural Engineering in SJC institute of
Technology, Chickballapur.

Mr.Shashi Kumar. A,
Assistant
Professor,
Department
of
Civil
Engineering, SJC institute of Technology,
Chickballapur. He has wide experience in
teaching field for over 15 years and
currently pursuing his Ph.D.
Dr.G.Narayana, Professor and Head of
Civil Engineering Department, SJC
institute of Technology, Chickballapur,
have a wide experience in teaching and
research in Structural Engineering field. He
is also a Structural Designer and Consultant
for many Projects.

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